Eight Head Vial Filler

Q: How does the machine prevent liquid wastage if a vial is missing?

The machine is equipped with a 'No Vial – No Filling' sensor system . If a vial is missing on the conveyor line at any of the eight filling stations, the sensors signal the machine to skip that specific filling cycle, ensuring no product is wasted and the machine remains clean.

Q: What materials are used to ensure pharmaceutical compliance?

To meet strict cGMP (current Good Manufacturing Practices) standards: Contact Parts: All parts that touch the product (syringes, nozzles, and delivery tubes) are made from AISI SS 316L . Body Structure: The main frame and non-contact components are made from AISI SS 304 with a matte finish, ensuring the machine is easy to sterilize and resistant to corrosion.

Description

Eight Head Vial Filler (also known as an Automatic Eight Head Vial Filling and Rubber Stoppering Machine) is a high-speed, compact pharmaceutical packaging machine designed for the precise filling and rubber stoppering of injectable liquids into glass vials. It is widely used in the pharmaceutical industry for medium to large batch production of sterile injectables, such as vaccines, antibiotics, and other parenteral drugs. The “eight head” refers to the eight filling stations (syringes or nozzles) that operate simultaneously, enabling high throughput while maintaining accuracy and compliance with GMP (Good Manufacturing Practice) standards.

Infeed: Sterilized vials are unscrambling-fed onto a delrin slat conveyor and spaced by an infeed starwheel.

Filling: Vials enter the eight-head rotary station; nozzles descend to fill from the bottom, halfway, or top (configurable for foam-sensitive liquids).

Stoppering: Filled vials move to the stoppering station, where a chute feeds rubber stoppers, pressed in by rotary rollers.

Outfeed: Completed vials exit via conveyor for capping/sealing (often integrated in full lines).

Quality Checks: Inline weighing, vision inspection, and rejection ensure compliance.

If you need details on specific models, pricing, or comparisons with multi-head machines, let me know!

Salient Features of Eight Head Vial Filler

Piston pump/Peristaltic pump aseptic filling.
Filling accuracy of ±0.5% to ±1%.
No cross contamination.
All Contact Parts Made from Stainless Steel 316L & framework by Stainless Steel 304.
Variable A.C. frequency drive for speed adjustment.
Suitable for the filling Volume of 2ml to 250ml.

Digital Vial Counter for counting production output.
“No Vial – Machine Stop” System.
On-line Mechanism., “No Vial – No Filling” System.
Easy to validate filling system for small/large batch production.
IQ/OQ documentation can be provided.
PLC system with Graphical User Interface. (Optional)

Working Principle of Eight Head Vial Filler

The incoming dry vials (sterilized and siliconized) are fed through the unscrambler and suitably guided on the moving Delrin slat conveyor belt at the required speed of the correct placement below filling unit.

The filling unit consists of Filling Head, Syringes & Nozzles; Syringes & Nozzles are made of AISI SS 316L materials. A Star Wheel is provided which holds the vial during filling operation. A sensor is provided for ”No Vial-No Filling” operation. Syringes are mounted on eccentric block and driving through bottom main gear box. Volume can be increase & decrease by increasing or decreasing stroke length of piston as per filling size. Syringes is having non return valve for sucking and delivering situation to avoid volume variation. Liquid reaches to filling nozzles through silicon transparent pipe. Nozzles having up & down movement with help of cam mechanism, and it come down when vial hold by starwheel for filling operation and starts filling when it starts to move up and after completion of filling operation, starwheel delivers two vials together on conveyor for rubber stoppering operation.

Stoppering unit consist of Star wheel, Vibrator unit and Bowl. The sterilized and siliconized rubber stoppers stored in the vibrator bowl moves vertically to the rubber stopper chute. The vial is hold firmly by starwheel, which will be in continuous rotary motion and vial which is coming from filling unit get in to starwheel and move in rotary direction along with starwheel, during movement it picks up the rubber stopper from the exit end of the chute and rubber stopper pressed by fix single pressing roller, which is spring loaded. Then vial further move on conveyor and collected on out feed starwheel for next sealing operation.

Technical Specification of Eight Head Vial Filler

Model	ALVF-120
Filling Heads	Eight
Production Rate	Up to 150 Vials/Minute
Vial Diameter	15mm to 70mm
Vial Height	25mm to 140mm
Filling Precision	±1%
Power Required	2 H.P.
Electrical Characteristics	440 Volts, 3 Phase, 50 Hertz
Overall Dimension	3000mm (L) x 945mm (W) x 1700mm (H)

* Power voltage can be adjusted as per customer’s domestic power voltage requirements.
* Rights of technical improvements & modification reserved.
* Illustrations & dimensions are shown for information purpose only.

Types of Vial Filling Machine

Automatic Vial Filling Machine

High Speed Vial Filling Machine

Vial Liquid Filling Machine

Vial Powder Filling Machine

Automatic Vial Filling and Rubber Stoppering Machine

Lab Scale Vial Filling Stoppering & Cap Sealing Machine

Injectable Vial Powder Filling & Stoppering Machine

Peristaltic Pump based Vial Filling Machine

Applications of Vial Filling Machine

Advantages of Eight Head Vial Filler

High Production Throughput

Exceptional Dosing Accuracy

cGMP Compliance and Sterility

Efficient Resource Management

Key Components of Eight Head Vial Filler

Construction and Materials: All parts in contact with the liquid or rubber stoppers are made from stainless steel 316 (SS 316) for corrosion resistance and easy sterilization/autoclaving. The machine includes a “No Vial, No Fill” system to prevent liquid wastage if a vial is missing.

Filling Mechanism: Utilizes eight precision syringes (glass or SS) with nozzles that move up and down via a cam mechanism. Filling occurs during rotary motion on a star wheel, ensuring gentle handling and repeatability. Fill volumes range from 0.5 mL to 100 mL, with accuracy of ±0.5% to ±1% depending on pump type (e.g., peristaltic or rotary piston pumps).

Stoppering System: Integrated vibrator-type rubber stoppering with a continuous rotary star wheel. It presses 20 mm diameter rubber stoppers with ±1% accuracy using spring-loaded rollers.

Transport and Control: Vials are fed via an infeed starwheel and conveyor. Equipped with an integrated touchscreen HMI for easy operation, servo-driven motors for smooth motion, and optional sterile isolator for aseptic environments.

Safety and Quality Controls: Includes sensors for vial detection, checkweighing stations (up to eight), inspection for stoppers, and automatic rejection of non-compliant vials via vacuum starwheel. Minimal particulate generation during sealing.

FAQ for Eight Head Vial Filler

What is the maximum production speed of the Eight Head Vial Filler?

The Eight Head Vial Filler is built for high-capacity production, offering an output of 120 to 150 vials per minute. The exact speed depends on the vial size, the neck diameter of the vial, and the specific fill volume being processed.

Can the machine handle different vial sizes and fill volumes?

Yes, the machine is highly flexible. It is designed to accommodate:

Vial Sizes: 5ml to 100ml (with standard change parts).
Fill Volumes: A wide range from 2ml to 100ml (up to 250ml with specific syringe sets). Adjustments for different volumes are made via the syringe stroke length, often controlled through a PLC interface in modern models.

How does the machine prevent liquid wastage if a vial is missing?

The machine is equipped with a “No Vial – No Filling” sensor system. If a vial is missing on the conveyor line at any of the eight filling stations, the sensors signal the machine to skip that specific filling cycle, ensuring no product is wasted and the machine remains clean.

What materials are used to ensure pharmaceutical compliance?

To meet strict cGMP (current Good Manufacturing Practices) standards:

Contact Parts: All parts that touch the product (syringes, nozzles, and delivery tubes) are made from AISI SS 316L.
Body Structure: The main frame and non-contact components are made from AISI SS 304 with a matte finish, ensuring the machine is easy to sterilize and resistant to corrosion.

What are the key safety and automation features?

The Eight Head Vial Filler includes several advanced features for safe, automated operation:

Safety Guards: Often features an acrylic cabinet with a safety interlock (machine stops if the door is opened).
Control Systems: Equipped with PLC automation and a touch-screen HMI for precise control over filling parameters.
Synchronization: The machine can be synchronized with an automatic rubber stoppering unit and capping machine for a complete, hands-free production line.

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